Self-Deploying Float

ABSTRACT

A self-deploying float assembly to support mechanical equipment such as aerators and mixers for use in water, wastewater and process water stream treatment basins and a method of installing same.

FIELD OF THE INVENTION

The present inventions relate to floats typically used in the water andwastewater treatment industry. More particularly, the present inventionsrelate to floats that may be installed in a folded position and whichunfold, i.e., self-deploy, upon placement in water or other liquid.

BACKGROUND OF THE INVENTION

Floats to suspend a mechanical device on the surface of liquid in abasin are fairly well known in the water and wastewater treatmentindustry. For example, surface mechanical aerators are floated on thesurface of water or wastewater to be aerated. Typical surface mechanicalaerators are sold by Aqua-Aerobic Systems, Inc. of Rockford, Ill. underthe trade names AquaJet® and AquaJet II®. In general, these devices havean aerator mounted to a rigid, typically circular float that must be ofsufficient size to generate enough buoyancy to support the aeratorequipment. Similarly, surface mechanical mixers are also supported onfloats on the surface of water or wastewater in a lagoon or basin. Atypical surface mechanical mixer is available from Aqua-Aerobic Systems,Inc. under the trade same AquaDDM®. Like an aerator, a mixer is mountedon a generally circular, solid float. Again, such floats must havefairly large diameters (if circular) so that they generate sufficientbuoyancy to support the associated mechanical equipment. The floats aretypically moored into place in the desired location so that they do notmove during use or otherwise.

Installing aerators, mixers and other mechanical devices and theirassociated floats is straightforward in open basins. Because the lagoonsor basins are open, the size of the mechanical device and associatedfloat does not impede installation or impose a size restriction on theequipment that may be used. Similarly, in new facilities, considerationmay be made in advance for the installation, repair and replacement ofequipment. However, many existing basins are enclosed in a building orother structure. There is limited ability in such structures to provideaccess to install new or replacement equipment. Thus, there is aphysical limitation on the size of equipment that may be installed inexisting enclosed locations, because access through existing roofs,walls and even doors is limited. Accordingly, while it is relativelyeasy to accommodate installation of equipment in new and open basins,many existing facilities have enclosed basins and have limited access tothe interior, making it more difficult to retrofit different devicesinto the location to accommodate changing needs or requirements.

For example, many drinking water treatment installations or treatmentsteps are enclosed. In the treatment of drinking water, certainby-products of disinfection, such as trihalomethanes (THMs) are formed.Increasing government regulations require the removal of THMs, which mayeffectively be done using surface mechanical aeration, the most commonform for which is floating aeration. However, because many existingdrinking water treatment facilities are enclosed, having roof structureswith limited openings available for the introduction of new equipment,traditional and known floats that support aerators and other equipmenton the surface of the basin are too large to fit within the availableopenings of such installations.

Thus, there is a need, particularly in the water and wastewatertreatment industry, to provide a float assembly that may fit through afenestration or other reasonably available or created opening of anenclosed treatment basin, while at the same time providing sufficientbuoyancy to support the associated equipment such as aerators, mixersand the like.

SUMMARY OF THE INVENTION

The present inventions preserve the advantages of known floats formechanical or other equipment and also provide new features andadvantages.

Therefore, it is an object of the present invention to provide a floatassembly that is sufficiently compact so that it may be installedthrough a fenestration in an enclosed basin.

It is another object of the present invention to provide a floatassembly that self-deploys upon placement into a liquid in a basin andprovides sufficient stability to support mechanical equipment.

An additional object of the present invention is to provide a floatassembly that may be used with a variety of mechanical equipment whichmay also be installed through a fenestration of an enclosed facility.

A further object of the present invention is to provide a float assemblythat may be in a folded condition for transportation and installationand which becomes unfolded and self-deployed upon placement in a liquidin a basin.

Still another object of the present invention is to provide a surfacemechanical mixer or aerator that may be retrofitted into an enclosedbasin used in conjunction with a self-deploying float assembly.

Yet an additional object of the present invention is to provide afoldable float assembly, the floats of which may be opened from a foldedposition and locked into an enfolded or deployed position.

Yet a further object of the present invention is to provide a floatassembly having segmented floats that fold vertically for shipping andinstallation through a structure opening and which self-deploys or maybe otherwise deployed to a horizontal, unfolded position.

Yet another object of the present invention is to provide a floatassembly having a compact footprint (or taking-up a small volume ofspace) for reduced shipping costs and ease of handling and installation,while at the same time having sufficient buoyancy to support mechanicalequipment.

Accordingly, the present inventions provide a self-deploying floatassembly including a central support bracket for use in a basin having aliquid level. The assembly further includes a plurality of floats, eachfloat having a proximal and distal end, a length and a cross-sectionalshape. A plurality of hinges, each hinge pivotably mounting the proximalend of each float to the central support bracket such that each floatmay pivot between a downward, generally vertical or folded position andan upward, generally horizontal or unfolded position for use, are alsoprovided. Preferably, the cross-sectional shape of each of the pluralityof floats is a hexagon or a diamond. The central support bracket of thefloat assembly is capable of accepting and securing a mechanical deviceand may include hoisting hooks for use during installation and removalof the assembly. Hinges and/or the central support bracket of the floatassembly may also be configured to prevent the floats from pivotingbeyond a generally horizontal position. In other embodiments of theinventions, the floats may be secured to the central support bracketwhen in a generally horizontal and deployed position. A mooring bracketmay also be provided.

The present inventions also provide a folding float assembly to supporta mechanical device (such as a mixer or aerator) on a liquid in a basin,the float assembly including a support bracket; a plurality of floats,each float having a proximal end, a distal end, a length and across-sectional shape; a plurality of hinges, each hinge pivotablymounted to the proximal end of each float to the support bracket suchthat each float may pivot from a downward, generally vertical positionupward to a generally horizontal position. The cross-sectional shape ofthe floats may be a hexagon, diamond or other cross-sectional shapes.Means for locking the floats to the support bracket in the generallyhorizontal and deployed position may also be provided. At least onefloat may also include a mooring bracket and hoisting hooks on thesupport bracket may also be provided.

The present inventions further provide for a method of installing aself-deploying float assembly through a fenestration in a structure andinto a basin containing a liquid having a liquid level. The steps of themethod include lowering a self-deploying float assembly through theopening in a roof so that the float deploys upon contact with theliquid, the self-deploying float assembly including a central supportbracket, a plurality of floats pivotably attached to the central supportbracket with a plurality of hinges which permit the plurality of floatsto pivot between a generally vertical position to a generally horizontalposition when placed in the liquid; locking the plurality of floats tothe central support bracket in the generally horizontal position; andinstalling mechanical equipment into said float assembly. The method mayalso include the step of mooring the float assembly and associatedmechanical equipment to a stationary post in the basin.

The present inventions still further provide a foldable float assemblyfor installation in an empty or dry basin, having a central supportbracket; a plurality of floats, each float having a proximal end and adistal end, a length and a cross-sectional shape; and, a plurality ofhinges, each hinge pivotably mounting the proximal end of each float tothe central support bracket such that each float may pivot between adownward, generally vertical position and an upward, generallyhorizontal position. The floats may also be secured to the centralsupport bracket when in the generally horizontal position and the hingesand the central support bracket may prevent the floats from pivotingbeyond a generally horizontal position. The foldable float of thepresent inventions may also provide a central support bracket that iscapable of accommodating a mechanical device. Preferably thecross-sectional shape of each of the plurality of floats is hexagonal.

INVENTOR'S DEFINITIONS OF THE TERMS

The following terms which may be used in the various claims and/orspecification of this patent are intended to have their broadest meaningconsistent with the requirements of law:

“Basin,” as used herein, is used in its broadest sense and includes,among other things, basins, tanks, lagoons and reservoirs used for atleast one step in the treatment of water, wastewater and process water.

“Structure opening” or “fenestration,” as used herein, is used in itsbroadest sense to refer to any opening, whether existing or created, ina roof, wall or other structure enclosing and/or covering a basin.

“Mechanical equipment,” as used herein, is used in its broadest sense toinclude any equipment to be supported by a float assembly in a basin,including but not limited to aerators, mixers and the like.

Where alternative meanings are possible, in either the specification orclaims, the broadest meaning is intended. All words used in the claimsare intended to be used in the normal, customary usage of grammar, thetrade and the English language.

BRIEF DESCRIPTION OF THE DRAWINGS

The stated and unstated objects, features and advantages of the presentinvention (sometimes used in the singular, but not excluding the plural)will become apparent from the following descriptions and drawings,wherein like reference numerals represent like elements in the variousviews, and in which:

FIG. 1 is a perspective view of a preferred embodiment of the presentinvention shown deployed in a basin and supporting a typical aerator onthe surface of a liquid;

FIG. 2 is a top plan view of a preferred float assembly of the presentinvention (without the associated mechanical equipment) in an unfoldedor deployed position;

FIG. 3 is a side plan view of the preferred float assembly of FIG. 2;

FIG. 3A is a detailed side view of the attachment of a float to thecentral support bracket of the present invention using a preferredsingle point hinge assembly, taken from insert 3A of FIG. 3;

FIG. 3B is a side view of the preferred hinge assembly of FIG. 3A, takenalong line 3B-3B of FIG. 3A;

FIG. 4 is a top plan view of the float assembly of the present inventionshown with the floats in a folded position;

FIG. 5 is a front plan view of a preferred float assembly of the presentinvention showing the central support bracket and one preferred floatattached thereto;

FIG. 6 is a side plan view of a portion of the central support bracketand one attached float of FIG. 5, also showing the preferred center ofgravity of the attached float;

FIG. 7 is a perspective view of the float assembly of the presentinvention showing a representative installation through a fenestrationof a typical enclosed basin;

FIG. 7A is a close-up perspective view of the preferred float assemblyduring its initial stage of installation through the fenestration on theroof;

FIG. 7B is a perspective view of the float assembly of FIG. 7A shownduring a later stage of a typical installation;

FIG. 7C is a perspective view of the preferred float assembly in stillfurther stages of installation, the assembly in dashed lines showingpartial deployment upon initial contact with the liquid in the basin andthe assembly in solid lines showing the fully deployed position;

FIG. 7D is a side view of the preferred float assembly shown in apartially deployed position similar to the stage of installation of theembodiment shown in dashed lines in FIG. 7C.

FIG. 7E is a side view of the preferred float assembly shown in a fullydeployed or unfolded position similar to the embodiment shown in solidlines in FIG. 7C; and,

FIG. 8 is a perspective view of a representative aerator being installedthrough an opening in the roof for placement onto the fully deployedfloat assembly.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Set forth below is a description of what is currently believed to be thepreferred embodiments or best representative examples of the inventionsclaimed. Future and present alternatives and modifications to theembodiments and preferred embodiments are contemplated. Any alternativesor modifications which Make insubstantial changes in function, purpose,structure or result are intended to be covered by the claims of thispatent.

Although not limited thereto, the present inventions have particularapplicability to use in existing water or wastewater treatmentfacilities include a basin 10 having a liquid level 14 that is enclosedby walls and a roof 11 (see FIGS. 7 and 8). In such facilities, oftenthe most efficient way to access the interior of the facility to installequipment is through a fenestration 12 or other opening in the roof 11at a point above the basin 10. Because of joists, beams and otherstructural members of the roof only a modest fenestration or opening 12exists or may be created in the roof 11 for purposes of installingequipment. It is through such an opening that the present inventions maybe introduced and are most advantageous.

It will also be understood by those of skill in the art that the presentinventions may be employed in basins 10 that are not enclosed or are dryat the time of installation, since the present inventions providedecreased shipping and storage costs. And, even in enclosed basins 10,the present inventions do not have to be introduced into the facilitythrough a fenestration 12 in the roof 11. Instead, for example, thepresent inventions may be introduced through a door or loading bay andthen installed in the basin 10. In addition, it will be understood thatthe present inventions are also applicable to and may be installed intofacilities in which the basin has been drained and there is no liquidlevel such that deployment of the floats is manual.

FIG. 1 shows a preferred embodiment of a float assembly 20 of thepresent invention shown fully deployed and supporting a typical piece ofmechanical equipment 60 (an aerator) installed in a typical basin 10.The float assembly 20 is moored in place in basin 10 using mooring post13. Details of a preferred embodiment of the self-deploying floatassembly 20 of the present invention is shown in more detail in FIGS.2-6. The stages of the installation and self-deployment of preferredfloat assembly 20 is shown in FIGS. 7-8.

Float assembly 20 includes a central support bracket 30. Support bracket30 includes an upper surface 31 and a lower surface 32. In the preferredembodiment, support bracket 30 is circular. However, it will beunderstood by those of skill in the art that other shapes, such assquare, trapezoid or rectangle, may also be used. Support bracket 30 isalso provided with an equipment opening 29 that is designed toaccommodate an aerator, mixer or other mechanical equipment 60. It willalso be understand that while opening 29 is shown as circular, anyshaped opening may be used consistent with the requirement of themechanical equipment 60 to be used and supported.

The lower surface 32 of central support bracket 30 is provided with aplurality of pivot brackets 33 (FIGS. 3, 5 and 6). Each pivot bracket 33is attached to and projects downwardly from the lower side 32 and eachpivot bracket includes an aperture 34. Pivot bracket 33 and associatedaperture 34 are intended to mate with double pivot brackets 50 and theirassociated apertures 51 which are attached to the proximal end 41 of thefloat 40 to pivotably mount float 40 to support member 30 in a hingedfashion as hereinafter described. In the preferred embodiment, there arefour pivot brackets 33 spaced evenly around the circumference of supportmember 30 to accommodate four floats 40 as hereinafter described. Itwill be understood by those of skill in the art that more or less thanfour floats 40 may be utilized, depending upon the application andrequired buoyancy.

Upper surface 31 of support bracket 30 is provided with a plurality ofhoisting hooks 35. Hoisting hooks 35 are provided to enable the floatassembly 20 to be lowered into the facility as hereinafter described(see e.g., FIG. 7). The support bracket 30 is also provided with aplurality of locking holes 36 that are used to secure floats 40 in anunfolded or generally horizontal position when fully deployed andinstalled, also as hereinafter described.

Each of the plurality of floats 40 has a proximal end 41, a distal end42 and a length L. Preferably, each float 40 is formed to have threeupper surfaces; namely, a generally horizontal top surface 44 and twonon-horizontal upper surfaces 43 and 45. It will be understood by thoseof skill in the art that the three upper surfaces 43, 44 and 45 may beformed from a single sheet of material or separate pieces of material.Preferred float 40 also includes three lower surfaces; namely, a lowergenerally horizontal surface 47 and two non-horizontal lower surfaces 46and 48, which also may be formed from a single sheet of material ormultiple pieces of material. The surfaces 43-48 of float 40 form agenerally hexagonal cross-section that is preferred for reasons ofcompactness and buoyancy. It will be understood by those of skill in theart that float 40 may have other cross-sectional shapes resulting inmore or less float surfaces, such as a rectangle, circle, diamond andthe like. However, the generally hexagonal cross-sectional shape ispreferred because it is more compact when in the folded position (seeFIGS. 4 and 7A) and provides sufficient buoyancy to support themechanical equipment 60. In addition, the generally horizontal topsurface 44 enables float 40 to be locked to central support bracket 30in the installed position, if desired.

In the preferred embodiment, float 40 is constructed from stainlesssteel. Surfaces 43-48, along with proximal end 41 and distal end 42,form a hollow, generally waterproof interior which is filled withpolyurethane foam to provide the desired buoyancy. It will be understoodby those of skill in the art that other materials of construction andfillers for buoyancy may be used. In addition, one or more floats 40 offloat assembly 20 may include a mooring bracket 15 that cooperates withmooring post 13 to keep the float assembly 20 and mechanical equipment60 in place within the basin 10 (see e.g., FIGS. 1 and 8).

The proximal end 41 of float 40 is provided with a double pivot bracket50. Double pivot bracket 50 includes a hole 51 (see FIGS. 3, 5 and 6).Double pivot bracket 50 is designed to sandwich single pivot bracket 33suspended from support bracket 30. Holes 34 of single pivot brackets 33align with holes 51 on double pivot brackets 50. A hinge bolt 38 isinserted through holes 34 and 51 and secured in place with hinge nuts39. In this manner, float 40 may pivot on support bracket 30 from adownward, generally vertical or folded position, upward to a generallyhorizontal or unfolded position (compare FIGS. 7A and 7E).

In a preferred embodiment, the center of gravity of floats 40 is locatedinside of the vertical pivot point as shown in FIG. 6. As a result, thefloats 40 are naturally biased or spread slightly outward as shown inFIGS. 6 and 7B. This is beneficial, since it allows the float 40 to moreeasily and surely deploy as the float assembly 20 is lowered into thewater 14 (see e.g., FIGS. 7C and 7D). To keep the silhouette of floatassembly 20 as small as possible and to aid in shipping, floats 40 maybe banded (not shown) into a tight cluster as shown in FIGS. 4 and 7A.Once the assembly 20 arrives at the site and the float assembly 20 islowered through and clears fenestration 12, the shipping band is cut orotherwise removed (compare FIGS. 7A and 7B). In a preferred embodiment,the float assembly 20 is then lowered into the liquid in basin 10 andself-deploys as shown in FIG. 7. Other embodiments may use manualdeployment or unfolding.

Once the floats 40 are fully deployed and/or unfolded, they may belocked in the horizontal position. Preferably, upper generallyhorizontal float surface 44 is provided with a threaded locking aperture52 near proximal end 41. Threaded locking aperture 52 is located onsurface 44 to align with hole 36 on support bracket 30. In this manner,when float 40 is in the unfolded, generally horizontal and deployedposition, float 40 may be secured to support bracket 30 using a lockbolt 53 inserted through hole 36 into threaded locking aperture 52. Itwill be understood by those of skill in the art that other ways to lockfloats 40 in the horizontal position may be used consistent with thepresent inventions. However, it is not required to lock the floats 40 ina horizontal position.

Having described the structure and arrangement of the components of apreferred embodiment of float assembly 20, installation of aself-deploying embodiment and operation will now be described,particularly by reference to FIGS. 7-8. As shown in FIG. 7, floatassembly 20 is lifted with a crane 17 or other hoisting method usingstraps 16 that are attached to hoisting hooks 35. During the initialstage of installation, the floats 40 are banded together (not shown) sothat float assembly 20 is in its most compact position (FIGS. 7 and 7A).Once float assembly 20 clears structure opening 12 (see FIG. 7B), theband (not shown) is cut or otherwise removed.

When float assembly 20 hits liquid level 14, floats 40 begin to deployfrom the generally vertical position to a horizontal position (see FIG.7C, dashed line, and FIG. 7D). Float assembly 20 continues to be lowereduntil floats 40 are in a generally fully horizontal position (see e.g.,FIG. 7C, solid line, and FIG. 7E). Floats 40 may then be locked in thehorizontal position to support bracket 30 using locking bolt 53 throughlocking hole 36 into threaded locking aperture 52 on surface 44 of float40. Upon installation, straps 16 are removed and float assembly 40 maybe moored to mooring post 13 with mooring bracket 15.

Once float assembly 40 is installed in basin 10 (see FIG. 7), thedesired mechanical equipment 60 is then lowered through structureopening 12 (see FIG. 8). Mechanical equipment 60 is then secured tocentral support bracket 30 through equipment opening 29. It will beunderstood by those of skill in the art that the installation describedis merely typical, and other methods of installation may be utilizeddepending upon the facility. For example, if installed in a dry basin,the basin bottom may be used, along with the weight of the assembly, tounfold the floats.

The above description is not intended to limit the meaning of the wordsused in or the scope of the following claims that define the invention.Rather, it is contemplated that future modifications in structure,function or result will exist that are not substantial changes and thatall such insubstantial changes in what is claimed are intended to becovered by the claims. Thus, while preferred embodiments of the presentinventions have been illustrated and described, it will be understoodthat changes and modifications can be made without departing from theclaimed invention. In addition, although the term “claimed invention” or“present invention” is sometimes used herein in the singular, it will beunderstood that there are a plurality of inventions as described andclaimed.

Various features of the present inventions are set forth in thefollowing claims.

1.-25. (canceled)
 26. A self-deploying float assembly to support amechanical device on a surface of a liquid in a water or wastewatertreatment basin, the self-deploying float assembly comprising: amechanical device; a central support bracket having a generally centralopening to receive and support the mechanical device; a plurality offloats, each float having at least an upper surface and a lower surface,a length and a cross-sectional shape, wherein a generally hollow chamberis formed along substantially the entire length of the floats, eachfloat further including a proximal end and a distal end; a plurality ofhinges, each hinge pivotably mounting the proximal end of each floatdirectly to a perimeter of the central support bracket such that eachfloat may, using the liquid, the weight of the assembly and the buoyancyof the floats, pivot between a downward, generally vertical positionprior to contact with the surface of the liquid and an upward, generallyhorizontal position upon placement of the assembly in the liquid for usein the water or wastewater treatment basin.
 27. The self-deploying floatassembly of claim 26 wherein the cross-sectional shape of each of saidplurality of floats is a hexagon.
 28. The self-deploying float assemblyof claim 26 wherein at least one float of the plurality of floatsincludes a mooring bracket to secure the float assembly in the water orwastewater treatment basin.
 29. The self-deploying float assembly ofclaim 26 wherein said hinges and central support bracket prevent saidfloats from pivoting beyond a generally horizontal position.
 30. Theself-deploying float assembly of claim 26 wherein the proximal end ofthe upper surface of the floats includes a first aperture and thecentral support bracket includes a second aperture such that each floatis secured to the central support bracket in a generally horizontalposition with a fastener cooperating with the first aperture on theupper surface of the float and the second aperture on the centralsupport bracket.
 31. The self-deploying float assembly of claim 30wherein the first aperture of the upper surface of each float is athreaded locking aperture for securing the float in a generallyhorizontal position to the central support bracket with a bolt.
 32. Theself-deploying float assembly of claim 26 wherein an upper surface ofthe central support bracket includes hoisting hooks.
 33. Theself-deploying float assembly of claim 26 wherein the generally hollowchamber is filled with a foam to provide buoyancy.
 34. Theself-deploying float assembly of claim 26 wherein the mechanical deviceis an aerator.
 35. The float assembly of claim 26 wherein the mechanicaldevice is a mixer.
 36. The float assembly of claim 26 wherein theplurality of floats is four floats.
 37. The float assembly of claim 26wherein the plurality of floats is three floats.